E-commerce package

ABSTRACT

A lidded container includes a tray and a hingedly attached lid. The tray includes a locking panel hingedly connected to a front tray wall. The lid includes corner gussets disposed on the interior surfaces of a lid front wall. When the lid is placed on the tray to close it, the locking panel is reverse folded against either the interior or exterior surface of the tray front wall. In this configuration, angled edges defined by the lid corner gussets mate with complementary angled edges of the locking panel to lock the removable lid to the tray.

REFERENCE TO RELATED APPLICATION

This application is a National Phase application of PCT Application PCT/US2018/13245, filed Jan. 11, 2018, which claims the benefit of U.S. provisional application Ser. No. 62/449,401 filed on Jan. 23, 2017, which is hereby incorporated by reference in its entirety.

BACKGROUND

The field of the invention relates generally to a package including a carton with hingedly attached lid, and more particularly to a carton suitable for use as an e-commerce shipping container.

In recent years, the use of e-commerce shipping containers has rapidly expanded as customers increasingly purchase items over the Internet. A carton suitable for rapid packing, quick closure, and secure containment is desirable.

SUMMARY

According to a first aspect of the invention there is provided a lidded container that includes a tray and a hingedly attached lid. The tray includes a bottom wall, front and rear walls, two side walls, and a locking panel hingedly connected to an upper edge of the front wall, and the hingedly attached lid includes a top wall, first and second lid side walls, a lid front wall, and first and second corner gussets disposed on an interior surface of the lid front wall, the first and second corner gussets defining respective first and second gusset angled edges. The lidded container is configured to be placed in a closed and locked configuration by placing the lid over an open top of the tray and pressing downwards so as to cause the locking panel to fold outwardly until its exterior surface is at least substantially adjacent to the exterior surface of the front wall, such configuration allowing the first gusset angled edge to mate with a first complementary angled edge of the locking panel, and the second gusset angled edge to mate with a second complementary angled edge of the locking panel so as to lock the removable lid to the tray.

Optionally the locking panel is substantially trapezoidal.

Optionally the first and second corner gussets are substantially triangular.

Optionally the tray portion includes first, second, third, and fourth tray corner gussets.

Optionally the lid front wall and lid side walls is positioned outward of the tray front wall and tray side walls.

Optionally at least one perforation is provided in the top wall for forming an opening into the container.

Optionally, at least one perforation is provided which when broken allows removal of at least a portion of the lid front wall and disengage at least one second gusset angled edge from its complementary angled edge of the locking panel.

Optionally the lid front wall defines an access notch in a lower edge of the lid front wall, the access notch configured to provide access to the locking panel when the lidded container is in the closed and locked configuration.

Optionally the locking panel defines a generally-rectangular notch in a lower edge of the locking panel.

Optionally the lid is configured to be unlocked from the tray by pressing inwardly on a portion of the locking panel that is exposed through the access notch to move the first and second gusset angled edges out of alignment with the first and second complementary angled edges, thereby allowing the lid to be unlocked from the tray.

In a second embodiment, a lidded container is disclosed which includes a tray with a hingedly attached lid. The tray includes a base wall, front and rear walls, two side walls, and a locking panel hingedly connected to an upper edge of the front wall. The hingedly attached lid includes a top wall, first and second lid side walls, a lid front wall, and first and second corner gussets disposed on an interior surface of the lid front wall, the first and second corner gussets defining respective first and second gusset angled edges. The lidded container is configured to be placed in a closed and locked configuration by placing the lid over an open top of the tray and pressing downwards so as to cause the locking panel to fold inwardly until its interior surface is at least substantially adjacent to the interior surface of the front wall, such configuration allowing the first gusset angled edge to mate with a first complementary angled edge of the locking panel, and the second gusset angled edge to mate with a second complementary angled edge of the locking panel so as to lock the removable lid to the tray.

Optionally the locking panel is substantially trapezoidal.

Optionally the first and second corner gussets are substantially triangular.

Optionally the tray includes first, second, third, and fourth tray corner gussets.

Optionally the lid front wall and lid side walls are positioned inward of the tray front wall and tray side walls.

Optionally at least one perforation is provided in the top wall for forming an opening into the container.

Optionally at least one perforation is provided which when broken allows removal of at least a portion of the tray front wall and disengage at least one second gusset angled edge from its complementary angled edge of the locking panel.

In a third embodiment, a blank is disclosed for forming a lidded container. The blank includes a tray portion configured to form a tray and a lid portion configured to form a lid. The tray portion includes a first plurality of panels that are hingedly connected to one another and include, in series, a locking panel, the locking panel defining first and second angled locking edges, a front panel configured to form a front tray wall in a set-up tray, a bottom panel configured to form a bottom wall in the set-up tray, and a rear panel configured to form a rear wall in the set-up tray. The lid portion includes a top panel configured to form a top wall in a set-up lid, a lid front panel hingedly connected along a front edge of the top panel and configured to form front wall in the set-up lid, and a pair of gusset panels configured to form corner gussets within the front wall in the set-up lid, the gusset panels each defining a gusset angled edge. From the blank a set-up lidded container is formed that is configured to be placed in a closed and locked configuration by placing the set-up lid over an open top of the set-up tray and pressing downwards so as to cause the locking panel to fold outwardly until its exterior surface is at least substantially adjacent to the respective exterior surface of the front tray wall, such configuration allowing each gusset angled edge to mate with one of the first and second angled locking edge so as to lock the set-up lid to the set-up tray.

Within the scope of this application it is envisaged that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings may be taken independently or in any combination thereof. For example, features described with one embodiment are applicable to all embodiments unless there is incompatibility of features.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a top plan view of a blank used to form one embodiment of a carton.

FIG. 2 is a perspective view of the blank shown in FIG. 1.

FIG. 3 is a perspective view of the assembled carton made from the blank of FIGS. 1 and 2, in an open configuration.

FIG. 4 is a perspective view of the assembled carton of FIG. 3, in a closed configuration.

FIG. 5 is a perspective view of the assembled carton of FIG. 4, with a partial cutaway showing details.

FIG. 6 is a perspective view of a blank used to form another embodiment of a carton.

FIG. 7 is a perspective view of a carton made from the blank of FIG. 6, in a partially assembled configuration.

FIG. 8 is a perspective view of a carton of FIG. 7, in a further assembled configuration.

FIG. 9 is a perspective view of the carton of FIG. 8, in an open configuration.

FIG. 10 is a perspective view of the carton of FIG. 9, with a locking flap folded downward.

FIG. 11 is a perspective view of the carton of FIG. 10, showing the lid partially closed over the tray.

FIG. 12 is a perspective view of the carton of FIG. 11, showing the lid fully closed over the tray.

FIG. 13 is a perspective view of the carton of FIG. 12, with a partial cutaway showing details.

FIG. 14 is a perspective view of the carton of FIG. 13, with a portion having been torn open.

FIG. 15 is a perspective view of another blank for forming a carton.

FIG. 16 is a perspective view of the assembled carton made from the blank of FIG. 15, in a closed configuration.

FIG. 17 is a perspective view of the carton of FIG. 16, with a partial cutaway showing details.

FIG. 18 is a top plan view of another blank used to form an embodiment of a carton.

FIG. 19 is a perspective view of the blank shown in FIG. 18.

FIG. 20 is a perspective view of the assembled carton made from the blank of FIGS. 18 and 19, in an open configuration.

FIG. 21 is a perspective view of the assembled carton of FIG. 20, in a partly closed configuration.

FIG. 22 is a perspective view of the assembled carton of FIG. 20, in a fully configuration.

FIG. 23 is a perspective view of the assembled carton of FIG. 20, with a partial cutaway showing details.

DETAILED DESCRIPTION

Detailed descriptions of specific embodiments of cartons and blanks are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all ways the invention may be embodied. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. Indeed, it will be understood that the crates and blanks described herein may be embodied in various and alternative forms. The FIGURES are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. Well-known components, materials or methods are not necessarily described in detail, to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.

In the embodiments detailed herein, the term “carton” refers, for the non-limiting purpose of illustrating the various features of the invention, to a container for shipping, transporting, storing, and/or dispensing articles, such as, e.g., one or more products being delivered to a consumer. However, it is contemplated that the teachings of the invention can be applied to various containers suitable for carrying a wide variety of articles.

Referring to FIG. 1, there is shown a blank 100 for forming a carton. The blank 100 includes a tray portion 101 and lid portion 103. The blank 100 is formed from a sheet of suitable substrate. It is to be understood that, as used herein, the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be recognized that one or other numbers of blanks may be employed, for example, to provide the carton described in more detail below.

In one or more embodiments, blank 100 can be formed from a paperboard, corrugated board, or cardboard in which one or both sides of the blanks, are printed and/or treated with one or more coatings, such as for example, one or more waterproof coatings and/or one or more coatings designed to provide a smooth and/or visually-attractive surface (e.g., a white or other colored surface). In one or more embodiments, informational or promotional material such as, e.g., a brand name or logo, can be printed on a treated side.

Referring to FIG. 1, blank 100 is generally rectangular and is generally symmetrical about a central longitudinal axis. Tray blank 100 has a base panel 114. Base panel 114 is hingedly connected to: a front panel 116 via transverse fold line 148; a rear panel 118 via transverse fold line 144; a first side panel 120 via longitudinal fold line 150; and a second side panel 122 via longitudinal fold line 146.

Foldably connected to the first side edge 176 of the front panel 116 is a first front gusset panel 124. Foldably connected to the second side edge 154 of the front panel 116 is a second front gusset panel 138. Foldably connected to a first side edge 172 of rear panel 118 is a first rear gusset panel 126. Foldably connected to a second side edge 170 of rear panel 118 is a second rear gusset panel 128.

Foldably connected to the outer edge 178 of front panel 116 is a locking panel 140. Locking panel 140 is generally trapezoidal in shape and includes an inwardly-angled first side edge 186 and an inwardly-angled second side edge 188. A generally rectangular notch 184 is struck from the locking panel outer edge 185. Notch 184 defines a notch edge 142

Blank 100 includes a lid portion 103 extending from tray portion 101. Top panel 194 is hingedly connected through transverse fold line 192 to rear panel 118. Top panel 194 is also connected to a first lid side panel 102 via longitudinal fold line 171; and to second side panel 104 via longitudinal fold line 175. Top panel 194 is also connected to lid front panel 198 via transverse fold line 173.

Foldably connected to the first front edge 125 of the first lid side panel 102 is a first front gusset panel 151. Foldably connected to the second front edge 127 of the second lid side panel 104 is a second front gusset panel 155. Front gusset panels 151, 155 respectively each have an angled edge 161, 165.

Lid front panel 198 includes a generally-rectangular access notch 129 struck from the first side panel outer edge 130.

FIG. 2 shows a perspective view of the blank 100 of FIG. 1.

FIG. 3 shows a perspective view of a carton 105 made from blank 100. The tray portion of carton 105 may be constructed by applying glue or other adhesive to: an outside surface of each of gusset panels 124, 126, 128 and 138 (or alternately to at least portions of an inside surface of side panels 120, 122). Gusset panels 124, 126, 128 and 138 may then be folded upward, and front and rear panels 116, 118 and side panels 120, 122 folded inwardly about their respective fold lines 148, 144, 150, 146 until they are generally perpendicular to base panel 114. This folding brings the outside surfaces of the gusset panels into contact with the inside surfaces, and the glue or other adhesive then secures them together. This results in the tray portion as seen to the front of FIG. 3.

Instead of glue or other adhesive, other methods may be used to attach together the panels. For example, staples, tape, stitching, double-side tape, pressure-sensitive adhesive, and other suitable methods may be used to attach together the panels. This is also true for the other embodiments described herein.

The hingedly attached lid portion of carton 105 may be constructed by applying glue or other adhesive to outside surfaces of gusset panel 151, 155 or to at least portions of the inside surface of lid front panel 198. The gusset panels 151, 155 may then be folded upwardly, and the first and second lid side wall panels 102, 104 folded inwardly about their respective fold lines 125, 127, 171, 175 until they are generally perpendicular to top panel 194. This folding brings the outside surfaces of gusset panels 151, 155 into contact with the inside surface of lid front panel 198 and secures them together. This results in lid portion as shown to the back of FIG. 3.

In some embodiments, carton 105 may include in its interior an adhesive sheet that may be of the type described in U.S. Pat. No. 9,340,317, the entirety of which is incorporated herein by reference. A lower surface of the adhesive sheet may be centered on and adhered to interior surface of base panel 114 (as shown in FIG. 3) during assembly of the carton 105. One or more articles 50 may be placed on the upper surface of adhesive sheet 106, and the adhesive sheet 106 may then be adhered to itself to envelop the article 50 and fix it securely in place within the carton 105. This may be desired to prevent damage to the article 50 during transport.

The carton 105 may be closed with its lid side panels 102, 104 overlapping and on the outside of tray side panels 120, 122. When closed, lid front panel 198 may overlap and be outside of tray front panel 116. To close the carton 105, as shown in FIG. 4, the lid portion is folded forward over the tray portion and pressed downwards. This forces the locking panel 140 to fold outwardly until its exterior surface (‘exterior’ in the sense as shown in FIG. 3) is substantially parallel and adjacent to (e.g., in face-contacting relationship with) the exterior surface of front panel 116. This configuration causes the angled edges 161, 165 of lid gussets 151, 155 to automatically mate with respective complementary angled edges 186, 188 of locking panel 140, thereby locking the lid in place to create a secure connection between the lid and tray. Advantageously, the lid can be locked to the tray without the need for an adhesive connection therebetween, although in certain embodiments glue or other adhesive may be used to strengthen the connection. Instead of glue or other adhesive, other methods may be used to strengthen the connection. For example, staples, tape, stitching, double-side tape, pressure-sensitive adhesive, and other suitable methods may be used. This is also true for the other embodiments described herein.

To open the lid, a user can push inwardly on the portion of locking panel 140 that is exposed to view through access notches 129. This moves the angled edges 186, 188 of locking panel 140 out of alignment with respective angled edges 161, 165 of gussets 151, 155 allowing the lid to be lifted open from the tray.

As another way to open carton 105, a user can place his fingers or thumbs at the edges of access notch 129 and move his fingers or thumbs outward toward the corners of the carton, between angled edges 161, 165 of lid gussets 151, 155 and angled edges 186, 188 of locking panel 140, then disengage the lid from the tray.

As another way to open carton 105, the lid and/or tray may be provided with one or more perforations or tear strips 196, 197 by which at least a portion of the lid may be removed or released from the tray. This method may be particularly useful if the lid is glued or otherwise secured to the tray.

As another way to open carton 105, the lid and/or tray may be provided with one or other perforations or tear strips by which at least a portion the lid may be removed to release the engagement between the tray and lid. This method, also, may be particularly useful if the lid is glued or otherwise secured to the tray. For example, at least portions of transverse fold line 173, first front edge 125, and/or second front edge 127 (see FIGS. 1 and 4) may be perforated to allow at least a portion of lid front panel 198 to be removed to disengage the lid from the tray.

In some embodiments, one or both sides of blank 100 or carton 105 may be treated with a water-proof or water-resistant coating. Water resistance may be considered particularly desirable based on any likelihood that carton 105 will be delivered to a location that is exposed to the elements.

FIG. 5 shows a perspective view of carton 105, with a cutaway portion on the front left corner to shows the angled edge 161 of lid gusset 151 locked into place against complementary angled edge 186 of locking panel 140. The lid gusset 151 and the locking panel 140 are substantially in a common plane that is tightly constrained (e.g. as a middle layer) between the more inward plane of tray front panel 116 and more outward plane of lid front panel 198. Thus, the lid is securely locked in place onto the tray.

In a variation of the carton 105, only one of the lid gussets may lock into place with an angled edge of locking panel 140. This may be sufficient to hold the lid shut, at least temporarily, for example until an adhesive connection has set between lid and tray. In some variations of the carton 105, the lid gussets 151, 155 may interlock with the locking panel 140 while having lid gussets with a shape other than substantially triangular, or a locking panel with a shape other than substantially trapezoidal.

FIGS. 6-14 show another embodiment of a blank 200 and a carton 205. Certain features are similar to features already described, and are designated with similar numerals in the 200's. This embodiment differs in certain aspects from the embodiment of FIGS. 1-5. For example, as shown in FIG. 6, tray gusset panels 224, 226, 228, and 238 may extend from side panels 220, 222 instead of extending from the tray front and rear panels. Also, the carton 205 may lack a notch in the outer edge of locking panel 240.

FIG. 7 shows a perspective view of a step in forming carton 205 from blank 200. Glue or other adhesive may be applied to an outside surface of gusset panels 224, 238 (or alternately to at least portions of an inside surface of tray front panel 216). Glue or other adhesive may be applied to an outside surface of gusset panels 251, 255 (or alternately to at least portions of an inside surface of lid front panel 298). Gusset panels 224, 238, 251, 255 may then be folded upward. Tray front panel 216, lid front panel 298, and side panels 202, 204, 220, 222 may be folded inwardly about their respective fold lines until they are generally perpendicular to base panel 214 and top panel 294. This folding brings the outside surfaces of the gusset panels into contact with the inside surfaces of tray front panel 216 and lid front panel 298, and the glue or other adhesive then secures them together.

Glue or other adhesive may then be applied to the ‘exterior’ surfaces of gusset panels 226, 228 (or to at least portions of the inside surface of rear panel 218. The gusset panels 226, 228 may then be folded inwardly about respective crease lines as shown in FIG. 8. Next, as shown in FIG. 9, rear panel 218 may be folded upwardly along its crease line with base panel 214. This brings the exterior surfaces of gusset panels 226, 228 into contact with an interior surface of rear panel 218 for adhesive attachment thereto. This results in the fully-assembled tray carton 205 shown in FIG. 9. A product item (not shown) may be loaded into carton 205.

Instead of glue or other adhesive, other methods may be used to attach together the panels. For example, staples, tape, stitching, double-side tape, pressure-sensitive adhesive, and other suitable methods may be used to attach together the panels.

Next, as seen in FIG. 10, locking panel 240 may be folded outwardly (arrow M1) until its exterior surface (‘exterior’ as seen in FIG. 9) is substantially parallel and adjacent to (e.g., in face-contacting relationship with) the ‘exterior’ surface of tray front panel 216. The natural flex or resilience of the paperboard may resist the folding, and cause locking panel 240 to remain flexed outward until the lid portion is closed over the tray.

As shown in FIG. 11, the lid may now be moved forward and over the tray to begin closing the carton 205. This configuration causes the angled edges 261, 265 of lid gussets 251, 255 to automatically mate with respective complementary angled edges 286, 288 of locking panel 240, thereby locking the lid in place to create a secure closure of the carton 205 as shown in FIG. 12. Advantageously, this secure closure can be achieved without the need for an adhesive connection therebetween, although in certain embodiments glue or other adhesive may be used to strengthen the connection. Instead of glue or other adhesive, other methods may be used to strengthen the connection. For example, staples, tape, stitching, double-side tape, pressure-sensitive adhesive, and other suitable methods may be used. This is also true for the other embodiments described herein.

As shown in FIG. 12, carton 205 may be closed with its lid side panels 202, 204 overlapping and on the outside of tray side panels 220, 222. When closed, lid front panel 298 may overlap and be outside of tray front panel 216.

FIG. 13 shows a perspective view of carton 205, with a cutaway portion on the front left corner to show the angled edge 261 of lid gusset 251 locked into place against complementary angled edge 286 of locking panel 240. The lid gusset 251 and the locking panel 240 are substantially in a common plane (middle layer) that is tightly constrained between the more inward plane of tray front panel 216 and the more outward plane of lid front panel 298. Thus, the lid is securely locked in place onto the tray.

To open the carton 205, a user can push inwardly on the portion of locking panel 240 that that is exposed to view through access notch 229. This moves the angled edges 286, 288 of locking panel 240 out of alignment with respective angled edges 161, 165 of gussets 151, 155 allowing the lid to be lifted up from the tray.

As another way to open carton 205, a user can place his fingers or thumbs at the edges of access notch 229 and move his fingers or thumbs outward toward the corners of the carton, between angled edges 161, 165 of the lid, and angled edges 286, 288 of the locking panel 240, to disengage the lid from the tray.

As seen in FIG. 14, yet another way to open carton 205 is to provide the lid and/or tray with one or more perforations or tear strips 296, 297 by which the lid or a portion thereof may be released from the tray. This method may be particularly useful if the lid is glued or otherwise secured to the tray.

In a variation of the carton 205, only one of the lid gussets may lock into place with an angled edge of locking panel 240. This may be sufficient to hold the lid shut, at least temporarily, for example until an adhesive connection has set between lid and tray. In some variations of the carton 205, the lid gussets 251, 255 may interlock with the locking panel 240 while having lid gussets with a shape other than substantially triangular, or a locking panel with a shape other than substantially trapezoidal.

As another way to open carton 205, the lid and/or tray may be provided with one or other perforations or tear strips by which at least a portion the lid may be removed to release the engagement between the tray and lid. This method, also, may be particularly useful if the lid is glued or otherwise secured to the tray. For example, at least portions of transverse fold line 273, first front edge 225, and/or second front edge 227 (see FIG. 12) may be perforated to allow at least a portion of lid front panel 298 to be removed to disengage the lid from the tray.

Glue or other adhesive may be used to strengthen the connection between the closed lid and the tray. Instead of glue or other adhesive, other methods may be used to strengthen the connection. For example, staples, tape, stitching, double-side tape, pressure-sensitive adhesive, and other suitable methods may be used.

In some embodiments, an adhesive sheet (as described earlier and shown in FIG. 3) may be used within the carton to secure its contents.

In some embodiments, one or both sides of blank 200 or carton 205 may be treated with a water-proof or water-resistant coating. Water resistance may be considered particularly desirable based on the increased likelihood that carton 205 may be delivered to a location that is exposed to the elements.

FIGS. 15-17 show another embodiment of a blank 300 and a carton 305. Certain features are similar to the earlier embodiments, and are designated with similar numerals in the 300's. This embodiment differs in certain aspects from the embodiment of FIGS. 6-14. For example, as shown in FIG. 15, blank 300 (and therefore resulting carton 305) may lack perforations for opening the carton.

FIG. 16 shows a perspective view of the completed carton 305. FIG. 17 shows a similar view, with a cutaway portion on the front left corner to show the angled edge 361 of lid gusset 351 locked into place against complementary angled edge 386 of locking panel 340. The lid gusset 351 and the locking panel 340 are substantially in a common plane (middle layer) that is tightly constrained between the more inward plane of tray front panel 316 and more outward plane of lid front panel 398. Thus, the lid is securely locked in place onto the tray.

As shown in FIG. 16, carton 305 may be closed with its lid side panels 302, 304 overlapping and on the outside of tray side panels 320, 322. When closed, lid front panel 398 may overlap and be outside of tray front panel 316.

To open the carton 305, a user can push inwardly on the portion of locking panel 340 that that is exposed to view through access notch 329. This moves the angled edges 386, 388 of locking panel 340 out of alignment with respective angled edges 361, 365 of gussets 351, 355 allowing the lid to be lifted up from the tray.

As another way to open carton 305, a user can place his fingers or thumbs at the edges of access notch 329 and move his fingers or thumbs outward toward the corners of the carton, between angled edges 361, 365 of the lid, and angled edges 386, 388 of the locking panel 340, to disengage the lid from the tray.

As another way to open carton 305, perforations may be provided in top panel 394 and /or other panels (See FIGS. 1-14). As another way to open carton 305, the lid and/or tray may be provided with one or other perforations or tear strips by which at least a portion the lid may be removed to release the engagement between the tray and lid. This method may be particularly useful if the lid is glued or otherwise secured to the tray. For example, at least portions of transverse fold line 373, first front edge 325, and/or second front edge 327 (see FIG. 16) may be perforated to allow at least a portion of lid front panel 398 to be removed in order to disengage the lid from the tray.

In some embodiments, an adhesive sheet (as described earlier and shown in FIG. 3) may be used within the carton to secure its contents. In a variation of the carton 305, only one of the lid gussets may lock into place with an angled edge of locking panel 340. This may be sufficient to hold the lid shut, at least temporarily, for example until an adhesive connection has set between lid and tray. In some variations of the carton 305, the lid gussets 351, 355 may interlock with the locking panel 340 while having lid gussets with a shape other than substantially triangular, or a locking panel with a shape other than substantially trapezoidal.

Glue or other adhesive may be used to strengthen the connection between the closed lid and the tray. Instead of glue or other adhesive, other methods may be used to strengthen the connection. For example, staples, tape, stitching, double-side tape, pressure-sensitive adhesive, and other suitable methods may be used.

In some embodiments, one or both sides of blank 300 or carton 305 may be treated with a water-proof or water-resistant coating. Water resistance may be considered particularly desirable based on the increased likelihood that carton 305 may be delivered to a location that is exposed to the elements.

FIGS. 18-23 show another embodiment of a blank 400 and a carton 405. Certain features are similar to features already described, and are designated with similar numerals in the 400's. In embodiment, as shown in FIG. 18, tray gusset panels 424, 426, 428, and 438 may extend from front panel 416 and rear panel 418. As will be seen in the following Figures, locking panel 440 may be turned inward in this embodiment.

Referring to FIG. 18, there is shown a blank 400 for forming a carton. In many aspects, blank 400 is similar to blank 100 previously described, although the shapes of various panels may differ slightly.

FIG. 19 shows a perspective view of the blank 400 of FIG. 18.

FIG. 20 shows a perspective view of a carton 405 made from blank 400. The tray portion of carton 405 may be constructed by applying glue or other adhesive to an inside surface of each of gusset panels 424, 426, 428 and 438 (or alternately to at least portions of an outside surface of side panels 420, 422). Front and rear panels 416, 418 and side panels 420, 422 may then be folded upwardly and inwardly about their respective fold lines 448, 444, 450, 446 until they are generally perpendicular to base panel 114. Gusset panels 424, 426, 428 and 438 may then be folded inward, to bring the inside surfaces of the gusset panels into contact with the surfaces of the front, rear and side panels, so that the glue or other adhesive secures the panels together. This results in the tray portion as seen to the front of FIG. 20.

The hingedly attached lid portion of carton 405 may be constructed by applying glue or other adhesive to inside surfaces of gusset panels 451, 455 or to at least portions of the outside surface of lid front panel 498. The first and second lid side panels 402, 404 may then be folded inwardly about their respective fold lines 471, 475 until they are generally perpendicular to top panel 494. Gusset panels 451, 455 may then be folded inwardly about their fold lines 425, 427 bringing their inner surfaces into contact with the outside surface of lid front panel 498, with the glue or other adhesive securing them together. This results in lid portion as shown to the back of FIG. 20.

Instead of glue or other adhesive, other methods may be used to attach together the panels. For example, staples, tape, stitching, double-side tape, pressure-sensitive adhesive, and other suitable methods may be used to attach together the panels.

To close carton 405, the locking panel 440 is folded inward as shown in FIG. 21, and the lid portion is folded forward over the tray portion and pressed downwards. This forces the locking panel 440 to fold further inwardly until its interior surface (‘interior’ in the sense as shown in FIG. 20) is substantially parallel and adjacent to (e.g., in face-contacting relationship with) the interior surface of front panel 416. As the lid portion is further closed, this configuration causes the angled edges 461, 465 of lid gussets 451, 455 to automatically mate with respective complementary angled edges 486, 488 of locking panel 440, thereby locking the lid in place to create a secure connection between the lid and tray. Advantageously, the lid can be locked to the tray without the need for an adhesive connection therebetween, although in certain embodiments glue or other adhesive may be used to strengthen the connection. Instead of glue or other adhesive, other methods may be used to strengthen the connection. For example, staples, tape, stitching, double-side tape, pressure-sensitive adhesive, and other suitable methods may be used.

As shown in FIGS. 21 and 22, carton 405 may be closed with its lid side panels 402, 404 inside of tray side panels 420, 422. When closed, lid front panel 498 may be inside of tray front panel 416. To better fit within the tray, for example to more readily clear the tray front panel when the lid is being closed, lid front panel 498 may be slanted slightly inward. One way to achieve this is to form front edges 425, 427 of the lid side panels 402,404 (these edges also being the hinge/fold lines attaching the gusset panel 451, 455) at an appropriate angle. Also, the angled edges 461, 465 may be adjusted accordingly to closely meet with the respective angled edges 486, 488 of locking panel 440. As best shown in FIG. 18, fold line 473 between top panel 494 and lid front panel 498 (and fold lines 471, 475 between the top panel and the lid side panels 402, 404) may be moved slightly inward to allow the lid to fit better within the tray.

To open the lid, a user can push his fingers between locking panel 440 that and lid front panel 498 to force angled edges 486, 488 of locking panel 440 out of alignment with respective angled edges 461, 465 of gussets 451, 455 allowing the lid to be lifted open from the tray.

As another way to open carton 405, the lid and/or tray may be provided with one or more perforations or tear strips (see FIGS. 1-14) by which the lid may be released from the tray, or a portion of the lid and/or tray removed. This method may be particularly useful if the lid is glued or otherwise secured to the tray.

As yet another way to open carton 305, the lid and/or tray may be provided with one or more perforations or tear strips by which at least a portion the lid may be removed to release the engagement between the tray and lid. This method, also, may be particularly useful if the lid is glued or otherwise secured to the tray. For example, at least portions of transverse fold line 448, first side edge 476 of the front panel, and/or second side edge 454 of the front panel (see FIGS. 18 and 22) may be perforated to allow at least a portion of tray front panel 416 to be removed in order to disengage the lid from the tray.

In some embodiments, carton 405 may include in its interior an adhesive sheet (as shown in FIG. 3) during assembly of the carton, for more securely holding articles placed within the carton. In some variations of the carton 405, only one of the lid gussets may lock into place with an angled edge of locking panel 440. This may be sufficient to hold the lid shut, at least temporarily, for example until an adhesive connection has set between lid and tray. In some variations of the carton 405, the lid gussets 451, 455 may interlock with the locking panel 440 while have lid gussets with a shape other than substantially triangular, or a locking panel with a shape other than substantially trapezoidal.

In some embodiments, one or both sides of blank 400 or carton 405 are treated with a water-proof or water-resistant coating. Water resistance may be considered particularly desirable based on any likelihood that carton 405 will be delivered to a location that is exposed to the elements.

FIG. 22 shows a perspective view of carton 405 in a closed configuration. FIG. 23 shows a front view with a cutaway portion on the front left corner to show the angled edge 461 of lid gusset 451 locked into place against complementary angled edge 486 of locking panel 440. The lid gussets 451, 455 and the locking panel 440 are substantially in a common plane that is tightly constrained between the plane of tray front panel 416 and lid front panel 498. Thus, the lid is securely locked in place onto the tray. Here, viewed from the front, the front wall of the carton includes as an outward layer the tray front panel 416, as a middle layer the locking panel 440 and lid gussets 451, 455, and as an inward layer the lid front panel 498.

Exemplary embodiments of blanks and methods for forming containers are described above in detail. The apparatus and methods are not limited to the specific embodiments described herein, but rather, components of apparatus and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods may also be used in combination with other containers and methods, and are not limited to practice with only the containers and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized with many other container applications.

Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

This written description uses examples to disclose the invention, including the best mode, and to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. 

What is claimed is:
 1. A lidded container comprising: a tray portion comprising a bottom wall, front and rear walls, two side walls, and a locking panel hingedly connected to an upper edge of the front wall; and a hingedly attached lid comprising a top wall, first and second lid side walls, a lid front wall, and first and second corner gussets disposed on an interior surface of the lid front wall, the first and second corner gussets defining respective first and second gusset angled edges; wherein the lidded container is configured to be placed in a closed and locked configuration by placing the lid over an open top of the tray and pressing downwards so as to cause the locking panel to fold outwardly until its exterior surface is at least substantially adjacent to the exterior surface of the front wall, such configuration allowing the first gusset angled edge to mate with a first complementary angled edge of the locking panel, and the second gusset angled edge to mate with a second complementary angled edge of the locking panel so as to lock the removable lid to the tray.
 2. The lidded container of claim 1, wherein the locking panel is substantially trapezoidal.
 3. The lidded container of claim 2, wherein the first and second corner gussets are substantially triangular.
 4. The lidded container of claim 1, wherein the tray portion comprises first, second, third, and fourth tray corner gussets.
 5. The lidded container of claim 1, wherein the lid front wall and lid side walls is positioned outward of the tray front wall and tray side walls.
 6. The lidded container of claim 1, with at least one perforation in the top wall for forming an opening into the container.
 7. The lidded container of claim 1, with at least one perforation which when broken allows removal of at least a portion of the lid front wall and disengage at least one second gusset angled edge from its complementary angled edge of the locking panel.
 8. The lidded container of claim 1, wherein the lid front wall defines an access notch in a lower edge of the lid front wall, the access notch configured to provide access to the locking panel when the lidded container is in the closed and locked configuration.
 9. The lidded container of claim 8, wherein the locking panel defines a generally-rectangular notch in a lower edge of the locking panel.
 10. The lidded container of claim 8, wherein the lid is configured to be unlocked from the tray by pressing inwardly on a portion of the locking panel that is exposed through the access notch to move the first and second gusset angled edges out of alignment with the first and second complementary angled edges, thereby allowing the lid to be unlocked from the tray.
 11. A lidded container comprising: a tray portion comprising a bottom wall, front and rear walls, two side walls, and a locking panel hingedly connected to an upper edge of the front wall; and a hingedly attached lid comprising a top wall, first and second lid side walls, a lid front wall, and first and second corner gussets disposed on an interior surface of the lid front wall, the first and second corner gussets defining respective first and second gusset angled edges; wherein the lidded container is configured to be placed in a closed and locked configuration by placing the lid over an open top of the tray and pressing downwards so as to cause the locking panel to fold inwardly until its interior surface is at least substantially adjacent to the interior surface of the front wall, such configuration allowing the first gusset angled edge to mate with a first complementary angled edge of the locking panel, and the second gusset angled edge to mate with a second complementary angled edge of the locking panel so as to lock the removable lid to the tray.
 12. The lidded container of claim 11, wherein the locking panel is substantially trapezoidal.
 13. The lidded container of claim 11, wherein the first and second corner gussets are substantially triangular.
 14. The lidded container of claim 11, wherein the tray portion comprises first, second, third, and fourth tray corner gussets.
 15. The lidded container of claim 11, wherein the lid front wall and lid side walls are positioned inward of the tray front wall and tray side walls.
 16. The lidded container of claim 11, with at least one perforation in the top wall for forming an opening into the container.
 17. The lidded container of claim 11, with at least one perforation which when broken allows removal of at least a portion of the tray front wall and disengage at least one second gusset angled edge from its complementary angled edge of the locking panel.
 18. A blank for forming a lidded container comprising: a tray portion configured to form a tray; and a lid portion configured to form a lid; wherein the tray portion comprises a first plurality of panels that are hingedly connected to one another and comprising, in series: a locking panel, the locking panel defining first and second angled locking edges; a front panel configured to form a front tray wall in a set-up tray; a bottom panel configured to form a bottom wall in the set-up tray; and a rear panel configured to form a rear wall in the set-up tray; wherein the lid portion comprises: a top panel configured to form a top wall in a set-up lid; a lid front panel hingedly connected along a front edge of the top panel and configured to form front wall in the set-up lid; a pair of gusset panels configured to form corner gussets within the front wall in the set-up lid, the gusset panels each defining a gusset angled edge; wherein a set-up lidded container is configured to be placed in a closed and locked configuration by placing the set-up lid over an open top of the set-up tray and pressing downwards so as to cause the locking panel to fold outwardly until its exterior surface is at least substantially adjacent to the respective exterior surface of the front tray wall, such configuration allowing each gusset angled edge to mate with one of the first and second angled locking edge so as to lock the set-up lid to the set-up tray. 